Flexible graphite composite fire retardant wallpaper and method

Abstract

A fire retardant flexible graphite composite is formed from particles of exfoliated flexible graphite and particles of unexfoliated graphite flake treated with an intercalating agent in a desired ratio based upon the strength and desired fire retardant properties of the composite. A wall or floor covering is formed by compressing the composite into a sheet and rolled into a roll.

What is claimed is: 
     
       1. A method of forming a fire proof flexible graphite covering for a wall or floor comprising the steps of: contacting particles of graphite flake with an intercalating agent for forming particles of intercalated graphite;   heating particles of intercalated graphite at an elevated temperature to form particles of exfoliated graphite;   combining particles of intercalated graphite with particles of exfoliated graphite in a predetermined proportion; and   compressing the combined particles into a densely compressed graphite sheet and rolling the compressed graphite sheet into a roll; wherein said particles of intercalated graphite are laid down to form a first bed of particles and wherein said particles of exfoliated graphite are laid down to form a second bed of particles with the second bed of particles superimposed over said first bed of particles for forming a two layer composite.   
     
     
       2. A method as defined in claim 1 wherein said two layer composite is compressed into a sheet. 
     
     
       3. A method as defined in claim 2 wherein the percentage of particles of intercalated graphite in said composite lies in a range of between 30-50%. 
     
     
       4. A method as defined in claim 1 wherein a third bed of intercalated graphite particles is superimposed over said second bed of particles to form a three layer covering. 
     
     
       5. A method as defined in claim 4 wherein the first and third beds are symmetrically arranged about the second bed with the percentage of particles of intercalated graphite in said composite in a range of between 10-60%.